Polaris 2011 RANGER RZR Service Manual page 245

CLUTCHING
Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
removal process.
Moveable Sheave - Bushing Removal
1. Remove clutch as outlined previously in this chapter.
2. Install handle end of the Piston Pin Puller (PN 2870386)
securely into bench vise and lightly grease puller threads.
Piston Pin Puller (PN 2870386)
3. Remove nut from puller rod and set aside.
Piston Pin Puller
(PN 2870386)
4. Install puller adapter (Item 10 from kit PN 2871226).
5. Install main adapter (Item D) onto puller.
Puller Tool (A,B)
Side "A" toward
sheave
Main
Adapter (D)
6. With towers pointing toward the vise, slide sheave onto
puller rod.
7. Install removal tool (Item A, B) into center of sheave with
"A side" toward sheave.
6.18
CAUTION
Main Puller Adaptor (#8)
(PN 5020632)
Nut (C)
Puller
Adapter (10)
Piston Pin
Puller
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
NOTE: Use Bushing Tool PA-47336.
8. Install nut (C) onto end of puller rod and hand tighten. Turn
puller barrel to increase tension on sheave if needed. Using
a hand held propane torch, apply heat around outside of
bushing until tiny smoke tailings appear.
9. Turn sheave counterclockwise on puller rod until it comes
free. Lift sheave off puller.
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
Drive Clutch Bushing Installation
1. Place main adapter (Item 8) on puller.
Puller Tool (A,B)
Side "A" toward
sheave
Bushing
Main Adapter
(8)
2. Apply Loctite 609 evenly to bushing bore inside
moveable sheave.
3. Set bushing in place on sheave.
4. Insert installation puller tool (Item A/B) with "A" side
down, into center of bushing.
NOTE: 800 EFI Clutch - Use Bushing Tool PA-47336.
5. With towers pointing upward, slide sheave, bushing and
tool onto puller rod.
6. Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
7. Turn sheave counterclockwise, making sure bushing is
drawn straight into bore. Continue until bushing is seated.
8. Remove nut from puller rod and set aside.
9. Remove sheave from puller.
10. Remove installation tool.
Nut (C)
Piston Pin
Puller